Ceramic transaction cards

ABSTRACT

A transaction card that includes a card body that can include a ceramic material. The card body can include a primary surface and a secondary surface, a laser marked feature disposed on the card body and a laser etched feature disposed on the card body. A method of making a transaction card can include forming a ceramic material slurry comprising a ceramic material and a binder, forming a green body from the ceramic material slurry, firing the green body at a firing temperature to create a fired ceramic body, grinding the fired ceramic body into a card body, and polishing a primary surface of the card body.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/070,414, entitled “METHOD OF MAKING CERAMIC-CONTAINING TRANSACTIONCARDS” and filed on Mar. 15, 2016, which is a divisional of U.S. patentapplication Ser. No. 15/004,445 entitled “CERAMIC-CONTAINING TRANSACTIONCARDS AND METHODS OF MAKING THE SAME” and filed Jan. 22, 2016. The '445application claims priority to and the benefit of U.S. ProvisionalPatent Application No. 62/113,013 entitled “CERAMIC-CONTAININGTRANSACTION CARDS AND METHODS OF MAKING THE SAME” and filed Feb. 6,2015. The contents of all are hereby incorporated by reference in theirentireties.

FIELD

This disclosure generally includes ceramic-containing transaction cardsuseful for facilitating payments and methods of making the same. Thetransaction cards may include other features such as a microchip (e.g.,smart card) and one or more antennae.

BACKGROUND

The proliferation of transaction cards (which allow the cardholder to,for example, pay with credit rather than cash) started in the UnitedStates in the early 1950s. Initial transaction cards were typicallyrestricted to select restaurants and hotels and were often limited to anexclusive class of individuals. Since the introduction of plastic creditcards, the use of transaction cards have rapidly proliferated from theUnited States, to Europe, and then to the rest of the world. Transactioncards are not only information carriers, but also typically allow aconsumer to pay for goods and services, without the need to constantlypossess cash. If a consumer needs cash, transaction cards allow accessto funds through, for example, an automatic teller machine (ATM).Transaction cards also reduce the exposure to the risk of cash lossthrough theft and reduce the need for currency exchanges when travelingto various foreign countries. Due to the advantages of transactioncards, hundreds of millions of cards are now produced and issuedannually, thereby resulting in a need for companies to differentiatetheir cards from competitor's cards.

Initially, the transaction cards often included the issuer's name, thecardholder's name, the card number, and the expiration date embossedonto the card. The cards also usually included a signature field on theback of the card for the cardholder to provide a signature to helpprotect against forgery and tampering. Thus, the cards served as devicesto provide data to merchants and the security associated with the cardwas the comparison of the cardholder's signature on the card to thecardholder's signature on a receipt along with the embossed cardholder'sname on the card.

Due to the popularity of transaction cards, numerous companies, banks,airlines, trade groups, sporting teams, clubs and other organizationshave developed their own transaction cards. As such, many companiescontinually attempt to differentiate their transaction cards andincrease market share not only by offering more attractive financingrates and low initiation fees, but also by offering unique,aesthetically pleasing features on the transaction cards. As such, manytransaction cards include not only demographic and account information,but the transaction cards also include graphic images, designs,photographs and security features.

Administrative and security issues (e.g., charges, credits, merchantsettlement, fraud, reimbursements, etc.) have increased due to theincreasing use of transaction cards. Thus, the transaction card industrystarted to develop more sophisticated transaction cards which allowedthe electronic reading, transmission, and authorization of transactioncard data for a variety of industries. For example, magnetic stripecards, optical cards, smart cards, and calling cards have been developedto meet the market demand for expanded features, functionality, andsecurity. In addition to the visual data, the incorporation of amagnetic stripe on the back of a transaction card allows digitized datato be stored in machine readable form. As such, magnetic stripe readersare used in conjunction with magnetic stripe cards to communicatepurchase data received from a cash register device on-line to a hostcomputer, along with the transmission of data stored in the magneticstripe (e.g., account information and expiration date).

Due to the susceptibility of the magnetic stripe to tampering, the lackof confidentiality of the information within the magnetic stripe and theproblems associated with the transmission of data to a host computer,integrated circuits were developed which may be incorporated intotransaction cards. These integrated circuit (IC) cards, known as smartcards, proved to be very reliable in a variety of industries due totheir advanced security and flexibility for future applications.However, even integrated circuit cards are susceptible tocounterfeiting.

As magnetic stripe cards and smart cards developed, the market demandedinternational standards for the cards. The card's physical dimensions,features and embossing area were standardized under the InternationalStandards Organization (“ISO”), ISO 7810 and ISO 7811. The issuer'sidentification, the location of particular compounds, codingrequirements, and recording techniques were standardized in ISO 7812 andISO 7813, while chip card standards were established in ISO 7813. Forexample, ISO 7811 defines the standards for the magnetic stripe which isa 0.5 inch stripe located either in the front or rear surface of thecard and which is divided into three longitudinally parallel tracks. Thefirst and second tracks hold read-only information with room for 79alphanumeric characters and 40 numeric characters, respectively. Thethird track is reserved for financial transactions and includesenciphered versions of the user's personal identification number,country code, currency units, amount authorized per cycle, subsidiaryaccounts, and restrictions.

More information regarding the features and specifications oftransaction cards can be found in, for example, Smart Cards by Jose LuisZoreda and Jose Manuel Oton, 1994; Smart Card Handbook by W. Rankl andW. Effing, 1997, and the various ISO standards for transaction cardsavailable from ANSI (American National Standards Institute), 11 West42nd Street, New York, N.Y. 10036.

The incorporation of machine-readable components onto transactions cardsencouraged the proliferation of devices to simplify transactions byautomatically reading from and/or writing onto transaction cards. Suchdevices include, for example, bar code scanners, magnetic stripereaders, point of sale terminals (POS), automated teller machines (ATM)and card-key devices.

Typical transaction cards are made from thermoplastic materials, such aspolyvinyl chloride (PVC) and polyethylene terephthalate (PET). However,these transaction cards are susceptible to being damaged or destroyed ifexposed to damaging environments. For example, transaction cards may bedamaged if left exposed to the elements for an extended period of time.Moisture and/or sunlight may break down the chemical bonds within thepolymers of typical transaction cards, such that transaction cards leftexposed to moisture and sunlight may become warped, cracked and/orunusable. In addition, thermoplastic transaction cards may be easilybent or may be broken or cut, thereby damaging the transaction card andrendering it unusable.

Therefore, a need exists for a transaction card that has both strengthand durability. Moreover, a need exists for a transaction card thatwithstands exposure to the elements, such as moisture or sunlight.

SUMMARY

The disclosed transaction card may include a card body comprising aceramic material, the card body including a primary surface and asecondary surface, a laser marked feature disposed on the card body anda laser etched feature disposed on the card body.

A method of making a transaction card may comprise forming a ceramicmaterial slurry comprising a ceramic material and a binder, forming agreen body from the ceramic material slurry, firing the green body at afiring temperature to create a fired ceramic body, grinding the firedceramic body into a card body, and polishing a primary surface of thecard body.

Additional features and advantages of the present invention aredescribed in, and will be apparent from, the detailed description of thepresently preferred embodiments and from the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a view of a primary surface of a ceramic transactioncard, in accordance with various embodiments;

FIG. 2 illustrates a view of a secondary surface of a ceramictransaction card, in accordance with various embodiments;

FIG. 3A illustrates an isometric view of a primary surface of a ceramictransaction card and a chamfered edge, in accordance with variousembodiments;

FIG. 3B illustrates a further isometric view of a primary surface of aceramic transaction card, in accordance with various embodiments;

FIG. 3C illustrates a close up view of a chamfered edge in accordancewith various embodiments;

FIG. 4A illustrates an isometric view of a primary surface of a ceramictransaction card and a rounded edge, in accordance with variousembodiments;

FIG. 4B illustrates a further isometric view of a primary surface of aceramic transaction card having a rounded edge, in accordance withvarious embodiments:

FIG. 4C illustrates a close up view of a rounded edge, in accordancewith various embodiments;

FIG. 5A illustrates an isometric view of a primary surface of a ceramictransaction card and a bullnose edge, in accordance with variousembodiments;

FIG. 5B illustrates a further isometric view of a primary surface of aceramic transaction card having a bullnose edge, in accordance withvarious embodiments;

FIG. 5C illustrates a close up view of a bullnose edge, in accordancewith various embodiments:

FIGS. 6A and 6B illustrate a primary surface of a ceramic transactioncard, in accordance with various embodiments;

FIG. 7 illustrates a secondary surface of a ceramic transaction card, inaccordance with various embodiments;

FIG. 8 illustrates an exploded view of a ceramic transaction card, inaccordance with various embodiments; and

FIG. 9 illustrates a method of making a ceramic transaction card, inaccordance with various embodiments, and FIG. 10 illustrates one exampleof the ceramic transaction card with multiple layers.

DETAILED DESCRIPTION

The detailed description of exemplary embodiments herein makes referenceto the accompanying drawings, which show exemplary embodiments by way ofillustration and their best mode. While these exemplary embodiments aredescribed in sufficient detail to enable those skilled in the art topractice the inventions, it should be understood that other embodimentsmay be realized and that logical, chemical and mechanical changes may bemade without departing from the spirit and scope of the disclosure.Thus, the detailed description herein is presented for purposes ofillustration only and not of limitation. For example, the steps recitedin any of the method or process descriptions may be executed in anyorder and are not necessarily limited to the order presented.

A transaction card may be a charge card, credit card, debit card, awardscard, prepaid card, telephone card, smart card, magnetic stripe card,bar code card, transponder, radio frequency card and/or the like. Thetransaction card may have an associated account number (e.g., embossed,printed, and/or accessed), which cardholders typically present tomerchants or use to interact with a machine, as part of a transaction,such as a purchase.

An “account number”, as used herein, includes any device, code, number,letter, symbol, digital certificate, smart chip, digital signal, analogsignal, biometric or other identifier/indicia suitably configured toallow the consumer to interact or communicate with the system, such as,for example, authorization/access code, personal identification number(PIN). Internet code, other identification code, and/or the like whichis optionally located on card. The account number may be distributed andstored in any form of plastic, ceramic, electronic, magnetic, radiofrequency, wireless, audio and/or optical device capable of transmittingor downloading data from itself to a second device. A customer accountnumber may be, for example, a sixteen-digit credit card number, althougheach credit provider has its own numbering system, such as thefifteen-digit numbering system used by American Express. Each company'scredit card numbers comply with that company's standardized format suchthat the company using a sixteen-digit format will generally use fourspaced sets of numbers, as represented by the number “0000 0000 00000000”. The first five to seven digits are reserved for processingpurposes and identify the issuing bank, card type and etc. In thisexample, the last sixteenth digit is used as a sum check for thesixteen-digit number. The intermediary eight-to-ten digits are used touniquely identify the customer.

In various embodiments, an account number may identify a consumer. Inaddition, in various embodiments, a consumer may be identified by avariety of identifiers, including, for example, an email address, atelephone number, a cookie id, a radio frequency identifier (RFID), abiometric, a geographic indicator and/or the like. The card may beassociated with, have access to or include a rewards account, chargeaccount, credit account, debit account, prepaid account, telephone card,embossed card, smart card, magnetic stripe card, bar code card,transponder, radio frequency card, key card, access card or anassociated account.

Ceramic-containing transaction cards and methods of making the same areprovided herein. The transaction cards may be standard-sized (i.e.,about 3% inches by about 2% inches by about 0.03 inches, and/or thosedimensions specified in ISO 7810 and ISO 7811, for example, for an“ID-1” card) or any other size specified in ISO 7810 and ISO 7811 or anyother size or configuration still usable as a transaction card (e.g., alarger transaction card, small transaction card, reduced sizetransaction card, foldable transaction card, the card being part ofanother device, the card being removed from another device). Moreover,the transaction card may have a magnetic stripe, an embedded microchip,a signature panel, a holographic image, and/or any feature typicallycontained on or within a transaction card. The transaction cards mayhave a card body comprised of a ceramic material. Various foldable cardsand/or transaction cards of non-traditional size may be found in thebelow U.S. Patent documents, all of which are herein incorporated byreference in their entirety: U.S. patent application Ser. No. 10/906,731filed on Mar. 3, 2005 and entitled System and Method forNon-Traditionally-Sized RF Transaction Card, U.S. patent applicationSer. No. 10/906,732 filed on Mar. 3, 2005 and entitled FoldableNon-Traditionally-Sized RF Transaction Card System and Method, whichissued as U.S. Pat. No. 7,156,301 on Jan. 2, 2007, U.S. patentapplication Ser. No. 10/436,343 filed on May 12, 2003 and entitledCompact or Convenient Transaction Cards, which issued as U.S. Pat. No.7,124,955 on Oct. 24, 2006, and U.S. patent application Ser. No.10/733,619 filed on Dec. 10, 2003 and entitled Foldable Transaction CardSystems, which issued as U.S. Pat. No. 7,147,151 on Dec. 12, 2006.

A card body may refer to a material in any shape or thickness. The cardbody may be shaped substantially as a transaction card and/or a layer ofa transaction card. In that regard, the material may be generally sizedas a transaction card though it may not meet ISO 7810 and/or 7811dimensions. A layer of a transaction card may refer to a material thathas the length and width (as defined herein) substantially near the ISO7810 and/or 7811 specified dimensions but has a thickness (as definedherein) less than the ISO 7810 and/or 7811 specified dimensions. In thatregard, a ceramic-containing transaction card may comprise a layer ofmetal or plastic bonded, laminated and/or otherwise coupled to a layerof a ceramic material. With momentary reference to FIG. 10, one can seean example of a first layer 1003 and/or a second layer 1006 of metal orplastic bonded, laminated, and/or otherwise coupled to a third layer1009 of a ceramic material.

In various embodiments, a card body may comprise a ceramic material. Aceramic material may comprise any suitable ceramic as well as anysuitable binder, dopant, or other adjunct (e.g. a dye) that may impartone or more physical characteristics to the ceramic. A ceramic materialmay comprise zirconium dioxide (zirconia), silicon carbide, boroncarbide, or the like. Suitable dopants include yttria (Y₂O₃), calciumoxide, aluminum oxide, silicon dioxide, and other rare earth metals andtheir oxides. Suitable binders may include sodium silicate, magnesiumaluminum silicates, polyvinyl alcohol, starches, carboxymethylcellulose,dextrin, and various the like. Various dyes may be used to alter thecolor of any portion or all of the card body.

In various embodiments, a card body may comprise a monolithic ceramic. Amonolithic ceramic may be a ceramic material that is formed (e.g., firedor sintered) without the use of reinforcing fibers. In that regard, amonolithic ceramic is fired and/or sintered as one component. However,in various embodiments, a card body may comprise a fiber reinforcedceramic. As used herein, a “fiber reinforced ceramic” may comprise anyfiber material that is reinforced with a ceramic material. For example,a carbon fiber-reinforced polymer may comprise carbon fiber reinforcedwith a ceramic material. In that regard, a fiber reinforced ceramic mayinclude a fibrous material such as carbon fibers, aramid fibers,fiberglass fibers, or similar fibers reinforced with a ceramic material,such zirconia and/or silicon carbide. Fibrous reinforced polymers tendto have a high strength to weight ratio, typically allowing for a stiffcomponent to be produced with relatively light weight.

Ceramic materials that have undergone firing and/or sintering (i.e.,fired ceramic materials) may be subject to grinding. In that regard, anysuitable abrasive may be used to grind a fired ceramic material. Forexample, a grinding wheel, grinding belt, or abrasive powder may be usedto grind a fired ceramic material. Grinding may proceed under dryconditions or wet conditions.

Grinding may be used to create a chamfered edge on a card body. Achamfered edge is a beveled edge connecting two surfaces. A beveled edgeis an edge of a structure that is not perpendicular to the faces of acard body. Grinding may be used to create a chamfered edge of a cardbody.

Grinding may be used to create a rounded edge on a card body. A roundededge is a semi-cylindrical edge connecting two surfaces. Grinding may beused to create a rounded edge of a card body.

Grinding may also be used to create a bullnose edge on a card body. Abullnose edge may comprise two convex surfaces extending from each of aprimary card surface and a secondary card surface to converge on asurface that is 90 degrees or about 90 degrees from the primary cardsurface and the secondary card surface, where the term about in thiscontext only means+/−5 degrees. Grinding may be used to create abullnose edge of a card body.

Fired ceramic materials may be subject to polishing, for example, aftergrinding. In that regard, any suitable polishing and/or buffingtechnique may be used to polish a fired ceramic material. For example, apolishing cloth or other textile may be used, with or without polishingaids such as polishing wax or polishing paste, may be applied to a firedceramic materials. Buffing may be performed with commercially availablebuffing equipment. Polishing and/or buffing may cause a fired ceramicmaterial to have a glossy and/or highly reflective finish.

In various embodiments, as described herein, a card body may comprise afired ceramic material. The card body may be polished and/or buffed to aglossy, highly reflective finish. In various embodiments, one or morelasers may be used to alter the card body. A laser may emit a focusedbeam of light having a given power output. Thus, a laser directed at asurface may have varying effects on the surface based upon the poweroutput of the laser and the duration of exposure. Lasers may emit alight over a small area, providing the ability for precision works.Moreover, lasers may be accurately and precisely controlled viaelectronic control systems for manufacturing ease. A typical laser maybe obtained from Virtek Laser Solutions, Inc. In various embodiments, a1064 nm, 25 W diode pumped YVO₄ laser may be used.

The effect a laser may have on a ceramic material depends in part on thepower output of the laser and the duration of exposure. For example,exposure for a short time to a low power laser may alter the surfacecharacteristics of a ceramic material, for example, changing a glossyfinished surface to a matte finish (i.e., one that is not as reflectiveto visible light). In contrast, exposure to a high power output laserfor a first duration, or a lower power output laser for a secondduration that is longer than the first duration, may cause a perforationof the ceramic material. In that regard, various laser processes may becharacterized by their effect on a ceramic material. These varioustechniques may be applied, in various embodiments, in the manufacture ofa transaction card. Lasers can provide marking of ceramic materials atdepths of as low as about 0.0003 inches. Though lasers may have variouspower outputs, for purposes of explanation, various laser processes maybe characterized by the total power during the exposure to a ceramicmaterial. Stated another way, the total power of laser exposure to asurface may be thought of as the amount of laser energy applied per unittime of exposure.

As used herein, “laser finishing” may refer to application of a laser toa ceramic material (e.g., a card body comprising a ceramic material) toremove and/or disrupt a glossy and/or highly reflective finish. In thatregard, laser finishing may impart a matte finish on a ceramic materialsurface.

As used herein, “laser marking” may refer to application of a laser to aceramic material (e.g., a card body comprising a ceramic material) toimpart a visible disruption to the ceramic material surface. Forexample, laser marking may remove a portion of ceramic material from aceramic material surface. In that regard, laser marking may impartvisible features to a ceramic material surface. For example, lasermarking may be used to impart readable text onto a ceramic materialsurface. In various embodiments, account indicia such as an accountnumber, an accountholder's name, a loyalty notation (e.g., “Member Since2001”), an expiration date, a signature, a brand name, or other indiciasuch as legal notices, regulatory compliance messages, phone numbers,URLs, email addresses, trademarks, pictures, graphics, bar codes, CCIDcode or any alphanumeric characters may be laser marked onto a ceramicmaterial surface. Laser marking involves the application of more totalpower from a laser than laser finishing.

As used herein, “laser etch” may refer to application of a laser to aceramic material (e.g., a card body comprising a ceramic material) toimpart an indentation to the ceramic material surface. For example,laser etching may remove a portion of ceramic material from a ceramicmaterial surface. In that regard, laser marking may impart visiblefeatures to a ceramic material surface that have a palpable depth. Forexample, laser etching may be used to impart various graphic featuresonto a ceramic material surface. In various embodiments, a logo, adecorative border, a brand name, and/or other features may be laseretched onto a ceramic material surface. Laser etching involves theapplication of more total power from a laser than laser marking.

As used herein, “laser perforation” may refer to application of a laserto a ceramic material (e.g., a card body comprising a ceramic material)to bore a hole completely through the card body. In that regard, laserperforation may remove all ceramic material in its path. For example,laser etching may completely remove ceramic material from a ceramicmaterial surface, leaving a through hole. In that regard, laserperforation may impart visible features to a ceramic material surfacethat traverse a thickness (as defined herein) of a card body. Forexample, laser perforation may be used to impart various graphicfeatures onto a ceramic material surface. In various embodiments, a logoand/or other features may be laser etched onto a ceramic materialsurface. Laser perforation involves the application of more total powerfrom a laser than laser etching. Laser cutting may be performed withsimilar laser parameters as laser perforation, but laser cutting may beused to remove ceramic material in any suitable manner.

Referring now to the drawings, FIGS. 1, 2, 3A, 3B and 3C illustrate aceramic transaction card 100 showing primary surface 122. The ceramictransaction card 100 may be composed of at least one layer of ceramicmaterial. Width 102 is shown relative to height 104 and thickness 106.Primary surface 122 contains various features that are produced throughlaser marking, laser finishing, laser etching, and laser perforation, asdescribed herein.

Chamfered edge 108 is shown connecting primary surface 122 to sidesurface 124. With reference to FIG. 3C, a close up of chamfered edge 108is illustrated. Primary surface 122 is shown connected to side surface124 by chamfered surface 302. Secondary surface 210 is shown connectedto side surface 124 by chamfered surface 306. Chamfered surface 302 maybe disposed between 30 degrees and 60 degrees from primary surface 122and from 30 degrees and 60 degrees from side surface 124. Chamferedsurface 306 may be disposed between 30 degrees and 60 degrees fromsecondary surface 210 and from 30 degrees and 60 degrees from sidesurface 124. Chamfered edge 108 may be produced by grinding and may bepolished. In various embodiments, chamfered edge 108 may formed in agreen body prior to firing the green body. In various embodiments,chamfered edge 108 is laser finished to create a matte finish. Invarious embodiments, however, an edge of ceramic transaction card 100may take any suitable profile, for example rounded or squared.

With momentary reference to FIGS. 4A-4C, rounded edge 422 is shownconnecting primary surface 122 to side surface 124. With particularreference to FIG. 4C, a close up of rounded edge 422 is illustrated.Primary surface 122 is shown connected to secondary surface 210 bysemi-cylindrical surface 420 of rounded edge 422. Semi-cylindricalsurface 420 may comprise a convex surface connecting primary surface 122to secondary surface 210. Rounded edge 422 may be produced by grindingand may be polished. In various embodiments, rounded edge 422 may formedin a green body prior to firing the green body. In various embodiments,rounded edge 422 is laser finished to create a matte finish.

With momentary reference to FIGS. 5A-5C, bullnose edge 556 is shownconnecting primary surface 122 to side surface 124. With particularreference to FIG. 5C, a close up of bullnose edge 556 is illustrated.Primary surface 122 is shown connected to secondary surface 210 byrounded surface 550, straight edge 552, and rounded edge 554. In thatregard, rounded surface 550 transitions primary surface 122 to straightedge 552. Straight edge 552 is about 90 degrees to primary surface 122,where the term “about” in this context only means+/−5 degrees. Roundedsurface 550 transitions secondary surface 210 to straight edge 552.Straight edge 552 is about 90 degrees to secondary surface 210, wherethe term “about” in this context only means+/−5 degrees. Bullnose edge556 may be produced by grinding and may be polished. In variousembodiments, bullnose edge 556 may formed in a green body prior tofiring the green body. In various embodiments, bullnose edge 556 islaser finished to create a matte finish.

Primary surface 122 may comprise one or more of a matte surface and aglossy surface. In various embodiments, primary surface 122 may bepolished to a glossy, highly reflective surface. Laser finishing may beused to transform a portion of the glossy surface to a matte finish.

Ceramic transaction card 100 may comprise pocket 112. Pocket 112 maycomprise an indentation or other depression that is offset from primarysurface 122. Microchip 110 is disposed in pocket 112. The position ofmicrochip 110 on the ceramic transaction card 100 may be standardized byindustry practice (for example, ISO 7816). Microchip 110 may include anintegrated antenna so that microchip 110 may facilitate wirelesstransactions. Microchip 110 may comprise any suitable recordable media,for example, an integrated circuit. Microchip 110 may comply with one ormore industry standards such as ISO 7819 and ISO 7816 to provide“smartcard” functionality to ceramic transaction card 100. In thatregard, microchip 110 may aid in the facilitation of financialtransactions. Many jurisdictions may now prefer a microchip intransaction cards. Microchip 110 may be disposed onto a card body in avariety of ways. Pocket 112 may be formed so that when microchip 110 isdisposed therein, a surface of microchip 110 will be flush orsubstantially flush with primary surface 122. An adhesive may bedisposed in the pocket 112 or on the microchip 110 prior to positioninga microchip 110 into a pocket 112 in ceramic transaction card 100. Anysuitable adhesive may be used. For example, ABLEBOND 931-1T1N1 may beused for this purpose. Further, in various embodiments, an insulatingmaterial may be disposed in the card body pocket to be positionedbetween the microchip and the card body so as to electrically insulatethe microchip and the card body. An adhesive may act as an insulatingmaterial. Any insulator may be used for this purpose.

Laser marked feature 116 is disposed on primary surface 122. Lasermarked feature may be produced by laser marking, as discussed above. Invarious embodiments, laser marked feature may include account indiciasuch as an account number, an accountholder's name, a loyalty notation(e.g., “Member Since 2001”), an expiration date, a signature, a brandname, or other indicia such as legal notices, regulatory compliancemessages, phone numbers, URLs, email addresses, trademarks, pictures,graphics, bar codes, CCID code or any alphanumeric characters.

Laser etched feature 120 is disposed on primary surface 122. Laseretched feature may be produced by laser etching, as discussed above. Invarious embodiments, laser etched feature may include a logo, and/or adecorative feature such as a border, though other patterns arecontemplated herein.

Secondary surface 210 may comprise gloss/matte feature 212. Gloss/mattefeature 212 may comprise a feature that comprises a gloss portion 206and matte portion 204. Together, gloss portion 206 and matte portion 204may be configured to display account indicia such as an account number,an accountholder's name, a loyalty notation (e.g., “Member Since 2001”),an expiration date, a signature, a brand name, or other indicia such aslegal notices, regulatory compliance messages, phone numbers, URLs,email addresses, trademarks, pictures, graphics, bar codes, CCID code orany alphanumeric characters. In that regard, alphanumeric characters maybe formed as gloss portion 206 against background of matte portion 204.

Magnetic stripe 208 may be disposed on secondary surface 210. Magneticstripe 208 may comprise any suitable recordable media. Magnetic stripe208 may be encoded via any encoding processes commonly used to encodethe transaction cards. Specifically, either or both of the recordablemedia, such as the magnetic stripe and/or the microchip, may be encodedto provide ceramic transaction card 100 with information beneficial tofacilitate a financial transaction. The recordable media may be read viaa magnetic stripe reader or a microchip reader.

Secondary surface 210 may comprise laser marked feature 214. Lasermarked feature 214 may comprise marked feature may include accountindicia such as an account number, an accountholder's name, a loyaltynotation (e.g., “Member Since 2001”), an expiration date, a signature, abrand name, or other indicia such as legal notices, regulatorycompliance messages, phone numbers, URLs, email addresses, trademarks,pictures, graphics, bar codes, CCID code or any alphanumeric characters.

Primary surface 122 and secondary surface 210 may comprise laserperforation 130. Laser perforation 130 may be a perforation in primarysurface 122 that forms a channel to secondary surface 210. In thatregard, laser perforation 130 comprises a hole through both primarysurface 122 and secondary surface 210. Laser perforation 130 maycomprise any suitable configuration and may comprise marked feature mayinclude account indicia such as an account number, an accountholder'sname, a loyalty notation (e.g., “Member Since 2001”), an expirationdate, a signature, a brand name, or other indicia such as legal notices,regulatory compliance messages, phone numbers, URLs, email addresses,trademarks, pictures, graphics, bar codes, CCID code or any alphanumericcharacters.

With reference to FIG. 9, method 400 is shown of manufacturing a ceramictransaction card, such as ceramic transaction card 100. A ceramicmaterial slurry may be formed in step 402. A ceramic material slurry maycomprise a solid phase and a liquid phase. The liquid phase may comprisewater, an alcohol, or any other suitable liquid for use in ceramicmaterial slurries. The solid phase may comprise any suitable ceramicmaterial as well as any suitable binder, dopant, or other adjunct (e.g.a dye) that may impart one or more physical characteristics to theceramic. A ceramic material may comprise zirconium dioxide (zirconia),silicon carbide, boron carbide, or the like. Suitable dopants includeyttria (Y₂O₃), calcium oxide, aluminum oxide, silicon dioxide, and otherrare earth metals and their oxides. Suitable binders may include sodiumsilicate, magnesium aluminum silicates, polyvinyl alcohol, starches,carboxymethylcellulose, dextrin, and various the like. Various dyes maybe used to alter the color of a card body. Dopants, dyes, adjuncts, andceramic materials may take the form of a powder. In various embodiments,zirconia and yttria comprise a solid phase of a ceramic material slurry.In various embodiments, zirconia comprises a solid phase of a ceramicmaterial slurry. The proportion of liquid phase to solid phase in theceramic material slurry may be adjusted according to variousmanufacturing parameters.

A ceramic material slurry may be formed into a green body in step 404. Agreen body may take the shape of a card body. In that regard, a greenbody generally having the shape of a transaction card in accordance withan ID-1 transaction card as defined by ISO 7810 and/or ISO 7811 isformed. In various embodiments, the green body may comprise a card bodyhaving dimensions of about 5% to 20% greater than the dimensions of atransaction card in accordance with an ID-1 transaction card as definedby ISO 7810 and/or ISO 7811. In various embodiments, the green body maycomprise a card body having dimensions of about 10% to 15% greater thanthe dimensions of a transaction card in accordance with an ID-1transaction card as defined by ISO 7810 and/or ISO 7811. It should benoted that a pocket such as pocket 112 may be formed into the green bodyprior to firing. However, in various embodiments, pocket 112 may belaser cut into a card body. In further embodiments, a green body may nothave a pocket 112 and, after firing, pocket 112 may be formed bymachining and/or grinding.

A green body may be fired in step 406. A green body may be fired in anysuitable manner. For example, a green body may be placed in a furnaceand exposed to elevated temperatures for a given period of time to forma fired green body. In various embodiments, the green body compriseszirconia. Firing may cause the green body to contract, thus decreasingits volume. In various embodiments, a green body may lose 10% of itsvolume during firing. In that regard, it is beneficial to size the greenbody so that the fired green body has dimensions larger than atransaction card in accordance with an ID-1 transaction card as definedby ISO 7810 and/or ISO 7811.

The fired green body may be subject to grinding in step 408 to form aground card body. Grinding may proceed according to any suitabletechnique, for example, use of a grinding wheel or belt. Grinding may bedry or may occur under liquid media. Grinding may be used to reduce thesize of the fired green body to dimensions that are within thespecification for a transaction card in accordance with an ID-1transaction card as defined by ISO 7810 and/or ISO 7811. Grinding mayalso impart a chamfered edge to the fired green body. A chamfered edgemay provide a pleasing tactile profile, as well as prevent a sharp edgefrom developing.

The ground card body may be subject to polishing in step 410 to form apolished card body. Polishing may proceed according to any suitabletechnique, for example, use of a polishing cloth with or without apolishing media such as polishing paste. Step 410 may comprise buffingaccording to any suitable buffing technique. Step 410 may result inimparting a glossy, highly reflective surface to the ground card body.

The polished card body may be subject to laser treatment in step 412. Asdiscussed above, laser treatment may comprise laser finishing, lasermarking, laser etching, and laser perforation. In that regard, laserfinishing, laser marking, laser etching, and laser perforation may beperformed on the polished card body to create the various featuresdescribed in connection with those techniques. In various embodiments, asingle laser is used for laser treating and set to different total poweroutputs to accomplish each task. Certain indicia, such as a cardholder'ssignature, may be captured digitally and used as a digital template toguide the laser in laser marking the cardholder's signature.

The polished card body may have recordable media applied in step 414. Amagnetic stripe may be disposed on the card body using an adhesive orother suitable coupling media. A microchip may be installed in thepocket as described herein.

With reference to FIG. 6A, ceramic transaction card 600 is shown. Width502 is shown relative to height 504. Ceramic transaction card 600 maycomprise pocket 512. Pocket 512 may comprise an indentation or otherdepression that is offset from primary surface 522. Integrated RF module510 is disposed in pocket 512. With momentary reference to FIG. 8,pocket 512 may include recess 702. Thus, integrated RF module 510 may beof non-uniform thickness. Thus, a portion of Integrated RF module 510may rest in pocket 512 but a portion of integrated RF module 510 mayrest in recess 702. The position of integrated RF module 510 on theceramic transaction card 600 may be standardized by industry practice(for example, ISO 7816). Integrated RF module 510 may include anintegrated antenna so that a microchip within integrated RF module 510may facilitate contact based “smartcard” transactions as well aswireless transactions via a wireless interface and an antenna ofintegrated RF module 510.

Integrated RF module 510 may thus comprise any suitable recordablemedia, for example, an integrated circuit. Integrated RF module 510 mayalso comprise a wireless interface configured to transmit wirelessinformation via an antenna integrated into integrated RF module 510.Integrated RF module 510 may comply with one or more industry standardssuch as ISO 7819 and ISO 7816 to provide “smartcard” functionality toceramic transaction card 600. Many jurisdictions may now prefer amicrochip in transaction cards. Integrated RF module 510 may be disposedonto a card body in a variety of ways. Pocket 512 may be formed so thatwhen integrated RF module 510 is disposed therein, a surface ofintegrated RF module 510 will be flush or substantially flush withprimary surface 522. An adhesive may be disposed in the pocket 512 or onthe integrated RF module 510 prior to positioning a integrated RF module510 into a pocket 512 in ceramic transaction card 600. Any suitableadhesive may be used. For example, ABLEBOND 931-1T1N1 may be used forthis purpose. Further, in various embodiments, an insulating materialmay be disposed in the pocket 512 to be positioned between theintegrated RF module 510 and the card body so as to electricallyinsulate the integrated RF module 510 and the card body. An adhesive mayact as an insulating material. Any insulator may be used for thispurpose.

Laser marked feature 536 is disposed on primary surface 522. Lasermarked feature may be produced by laser marking, as discussed above. Invarious embodiments, laser marked feature may include account indiciasuch as an account number, an accountholder's name, a loyalty notation(e.g., “Member Since 2001”), an expiration date, a signature, a brandname, or other indicia such as legal notices, regulatory compliancemessages, phone numbers, URLs, email addresses, trademarks, pictures,graphics, bar codes, CCID code or any alphanumeric characters.

Laser etched features 516 and 520 is disposed on primary surface 522.Laser etched feature may be produced by laser etching, as discussedabove. In various embodiments, laser etched feature may include a logo,and/or a decorative feature such as a border, though other patterns arecontemplated herein.

With reference to FIG. 6B, in various embodiments, microtype 650 may bedisposed adjacent to, or around, laser etched feature 520. Microtype 650may comprise laser etched or laser marked features, such as text, insmall type, for example, using font size 9 (˜0.125 inches) and below.Microtype 650 may comprise account indicia such as an account number, anaccountholder's name, a loyalty notation (e.g., “Member Since 2001”), anexpiration date, a signature, a brand name, and the like. In thisregard, microtype 650 serves as a security and personalization feature,making ceramic transaction card 600 more resistant to compromise.

With reference to FIG. 7, secondary surface 720 may comprise gloss/mattefeature 704. Gloss/matte feature 704 may comprise a feature thatcomprises a gloss portion 716 and matte portion 714. Together, glossportion 716 and matte portion 714 may be configured to display accountindicia such as an account number, an accountholder's name, a loyaltynotation (e.g., “Member Since 2001”), an expiration date, a signature, abrand name, or other indicia such as legal notices, regulatorycompliance messages, phone numbers, URLs, email addresses, trademarks,pictures, graphics, bar codes, CCID code or any alphanumeric characters.In that regard, alphanumeric characters may be formed as gloss portion716 against background of matte portion 714.

Magnetic stripe 508 may be disposed on secondary surface 720. Magneticstripe 508 may comprise any suitable recordable media. Magnetic stripe508 may be encoded via any encoding processes commonly used to encodethe transaction cards. Specifically, either or both of the recordablemedia, such as the magnetic stripe and/or the microchip, may be encodedto provide ceramic transaction card 600 with information beneficial tofacilitate a financial transaction. The recordable media may be read viaa magnetic stripe reader or a microchip reader.

Secondary surface 720 may comprise signature feature 706. Signaturefeature 706 may include a signature. The signature may be laser markedor laser etched. However, in various embodiments, signature panel 710may be disposed on secondary surface 720 and signature feature 706 maycomprise a handwritten signature.

Ceramic transaction cards have a number of advantages over conventionaltransaction cards comprised of plastic or metal. Ceramic materials maybe very hard and thus ceramic transaction cards may resist scratching.Ceramic transaction cards may be more resistant to deformation thatplastic or metal. Combinations of various features found in ceramictransaction cards described herein may be very difficult to reproducewithout costly equipment and know-how. Thus, the risk of fraudulentreproduction of ceramic transaction cards is reduced, thus leading tomore security. Ceramic transaction cards may further provide a luxuriouslook and feel, which may be beneficial in the marketplace.

In various embodiments, cards, components, modules, and/or engines ofthe system may be implemented in association with micro-applications ormicro-apps. Micro-apps are typically deployed in the context of a mobileoperating system, including for example, a WINDOWS® mobile operatingsystem, an ANDROID® Operating System, APPLE® IOS®, a BLACKBERRY®operating system and the like. The micro-app may be configured toleverage the resources of the larger operating system and associatedhardware via a set of predetermined rules which govern the operations ofvarious operating systems and hardware resources. For example, where amicro-app desires to communicate with a device or network other than themobile device or mobile operating system, the micro-app may leverage thecommunication protocol of the operating system and associated devicehardware under the predetermined rules of the mobile operating system.Moreover, where the micro-app desires an input from a user, themicro-app may be configured to request a response from the operatingsystem which monitors various hardware components and then communicatesa detected input from the hardware to the micro-app.

As used herein, any terms similar to “identifier” may be any suitableidentifier that uniquely identifies an item. For example, the identifiermay be a globally unique identifier (“GUID”). The GUID may be anidentifier created and/or implemented under the universally uniqueidentifier standard. Moreover, the GUID may be stored as 128-bit valuethat can be displayed as 32 hexadecimal digits. The identifier may alsoinclude a major number, and a minor number. The major number and minornumber may each be 16 bit integers.

The card or associated systems may include or interface with anyaccounts, devices, and/or a transponder and reader (e.g. RFID reader) inRF communication with the transponder (which may include a fob), orcommunications between an initiator and a target enabled by near fieldcommunications (NFC). Typical devices may include, for example, a keyring, tag, card, cell phone, wristwatch or any such form capable ofbeing presented for interrogation. Moreover, the card, system, computingunit or device discussed herein may include a “pervasive computingdevice,” which may include a traditionally non-computerized device thatis embedded with a computing unit. Examples may include watches,Internet enabled kitchen appliances, restaurant tables embedded with RFreaders, wallets or purses with imbedded transponders, etc. Furthermore,a device or financial transaction instrument may have electronic andcommunications functionality enabled. For example, by: a network ofelectronic circuitry that is printed or otherwise incorporated onto orwithin the transaction instrument (and typically referred to as a “smartcard”); a fob having a transponder and an RFID reader; and/or near fieldcommunication (NFC) technologies. For more information regarding NFC,refer to the following specifications all of which are incorporated byreference herein: ISO/IEC 18092/ECMA-340, Near Field CommunicationInterface and Protocol-1 (NFCIP-1); ISO/IEC 21481/ECMA-352, Near FieldCommunication Interface and Protocol-2 (NFCIP-2); and EMV 4.2 availableat http://www.emvco.com/default.aspx.

It should be noted that various changes and modifications to thepresently preferred embodiments described herein will be apparent tothose skilled in the art. Such changes and modifications may be madewithout departing from the spirit and scope of the present invention andwithout diminishing its attendant advantages. It is, therefore, intendedthat such changes and modifications be covered by the appended claims.

Benefits, other advantages, and solutions to problems have beendescribed herein with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any elements that maycause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as critical, required, or essentialfeatures or elements of the invention. The scope of the invention isaccordingly to be limited by nothing other than the appended claims, inwhich reference to an element in the singular is not intended to mean“one and only one” unless explicitly so stated, but rather “one ormore.” Moreover, where a phrase similar to ‘at least one of A, B, and C’is used in the claims, it is intended that the phrase be interpreted tomean that A alone may be present in an embodiment, B alone may bepresent in an embodiment, C alone may be present in an embodiment, orthat any combination of the elements A, B and C may be present in asingle embodiment; for example, A and B, A and C, B and C, or A and Band C. Although the invention has been described as a method, it iscontemplated that it may be embodied as computer program instructions ona tangible computer-readable carrier, such as a magnetic or opticalmemory or a magnetic or optical disk. All structural, chemical, andfunctional equivalents to the elements of the above-described exemplaryembodiments that are known to those of ordinary skill in the art areexpressly incorporated herein by reference and are intended to beencompassed by the present claims. Moreover, it is not necessary for adevice or method to address each and every problem sought to be solvedby the present invention, for it to be encompassed by the presentclaims. Furthermore, no element, component, or method step in thepresent disclosure is intended to be dedicated to the public regardlessof whether the element, component, or method step is explicitly recitedin the claims. No claim element herein is to be construed under theprovisions of 35 U.S.C. 112(f), unless the element is expressly recitedusing the phrase “means for.” As used herein, the terms “comprises”,“comprising”, or any other variation thereof, are intended to cover anon-exclusive inclusion, such that a process, method, article, orapparatus that comprises a list of elements does not include only thoseelements but may include other elements not expressly listed or inherentto such process, method, article, or apparatus.

Therefore, we claim:
 1. A transaction card manufactured by a process of:creating a ceramic card body comprising a binder in a ceramic materialand fiber reinforcing the ceramic material; laminating a layer of metalto a primary surface of the ceramic card body; creating a pocket in theprimary surface of the ceramic card body of the transaction card, thepocket extends through the layer of metal; depositing a magnetic stripeand a signature panel on a secondary surface of the ceramic card body;creating a recess comprising an opening in the pocket; disposing aninsulated material in the pocket and positioned between an integratedradio frequency (RF) module and the ceramic card body, the insulatedmaterial acting as an adhesive and to electrically insulate theintegrated RF module and the ceramic card body disposing an entirety ofa first side of the integrated RF module into the pocket, such that anouter portion of the first side of the integrated RF module rests in thepocket; and resting an inner portion of the first side of the integratedRF module in the opening of the recess.
 2. The transaction card of claim1 manufactured by the process further comprising laser finishing theprimary surface to add a laser matte feature disposed directly in theceramic material, wherein the laser matte feature comprises at least aportion of the primary surface.
 3. The transaction card of claim 1manufactured by the process further comprising laser cutting the primarysurface to form a chamfered edge between the primary surface and a sidesurface.
 4. The transaction card of claim 1 manufactured by the processfurther comprising laser cutting the pocket into the primary surface. 5.The transaction card of claim 1 manufactured by the process furthercomprising: forming a ceramic material slurry comprising the ceramicmaterial, the binder, and the fiber; forming a green body from theceramic material slurry; firing the green body at a firing temperatureto create a fired green body; grinding the fired green body into theceramic card body; and polishing the primary surface of the ceramic cardbody.
 6. The transaction card of claim 1 manufactured by the processfurther comprising leveling a second side of the integrated RF module tobe flush with the primary surface.
 7. The transaction card of claim 1manufactured by the process further comprising extending the recess in adirection of the secondary surface.
 8. A transaction card, comprising: aceramic card body comprising a fiber-reinforced ceramic material; ametal layer laminated to a primary surface of the ceramic card body; apocket in the primary surface of the ceramic card body, the pocketextending through the metal layer; an integrated radio frequency (RF)module located within the pocket, the integrated RF module comprising anantenna; an electrically insulated material in the pocket positionedbetween the integrated RF module and the ceramic card body, theelectrically insulated material acting as an adhesive to bind theintegrated RF module to the ceramic card body; and a magnetic stripeplaced on a secondary surface of the ceramic card body.
 9. Thetransaction card of 8, wherein a first side of the integrated RF moduleis flush with the primary surface of the ceramic card body.
 10. Thetransaction card of 8, wherein: the pocket has a recess; and theintegrated RF module is positioned with an entirety of a first side ofthe integrated RF module in the pocket, such that an outer portion ofthe first side rests in the pocket and the inner portion of the firstside rests in the recess of the pocket.
 11. The transaction card of 8,further comprising a laser matte feature disposed on the primarysurface.
 12. The transaction card of 8, further comprising a chamferededge between the primary surface and a side surface.